Integrally formed roof rack

ABSTRACT

A vehicle roof panel includes a roof portion and roof rack portion with an integrally embossed portion defined by longitudinally extending spaced apart side portions. A side rail is attached to each of the side portions. A cross member has connectors for selectively and slidably interconnecting to the side rail thereby retaining the cross member elevated above the planar surface of the roof panel.

BACKGROUND OF THE INVENTION

[0001] 1. Field of Invention

[0002] The present invention relates to an automotive roof panel. Moreparticularly, the present invention relates to an automotive roof panelhaving an integrally formed roof rack portion. 2. Description of theRelated Art

[0003] Minivans and sport utility vehicles are commonly purchased fromthe factory with a luggage or sport rack mounted on the roof of thevehicle. Currently, the roof racks are separate components from thevehicle body and must be assembled either as a separate operation in thefactory, or at the dealer, prior to delivery to the customer. An exampleof such a roof rack is illustrated in U.S. Pat. No. 5,924,614.

[0004] Additionally, current roof racks are only available in black. Noattempts have been made to color coordinate the roof rack with the colorof the vehicle.

[0005] The typical roof rack structure is a separate assembly thatrequires piercing the roof panel structure to attach the roof rack,thereby, allowing a possible ingress for water or other material.

[0006] Therefore, it is desirable to produce a one piece roof panel foran automobile that has a roof rack portion molded into the roof panel.

SUMMARY OF THE INVENTION

[0007] The disadvantages of the prior art may be overcome by providing aroof panel with an integrally molded roof rack.

[0008] It is desirable to simplify the manufacturing steps required toproduce an automobile roof panel with a roof rack, by negating the needto attach a separate roof rack assembly.

[0009] According to one aspect of the invention, there is provided avehicle roof panel assembly comprising a one piece panel having agenerally planar surface and an embossed portion defined bylongitudinally extending and generally parallel, spaced apart, sideportions. At least one connector is coupled to each of the side portionsand at least one cross member extends transversely between the sideportions and is coupled to each of the connectors. The side portions andthe connectors elevate and retain the cross member above the planarsurface of the roof panel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a partially broken perspective view of a roof panelassembly incorporating the aspects of the present invention; and

[0011]FIG. 2 is a partially broken cross-sectional view of the siderails, connectors and cross member of the roof panel assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0012] Referring to FIG. 1 there is shown a roof panel assembly,generally denoted at 10. The roof panel 10 is preferably formed of asolid body, one piece long-fiber reinforced thermoplastic, such asreinforced polypropylene or thermoset plastic. However, it is alsopossible to die stamp sheet metal in accordance with the presentinvention.

[0013] The roof panel 10 includes a roof portion 12 and a roof rackportion 14. The roof portion 12 includes a generally smooth planar area16 with an appropriate curvature or contour, according to the vehicledesign and specifications, which terminates at the front at a windshieldopening 18.

[0014] The windshield opening 18 is provided with an appropriate flangestructure 20 such that a glass windshield and seal can be mounted flushwith the roof panel 10. In the illustrated embodiment, the roof portion12 includes a pillar portion 22 for integrating and connecting with thestructural A-pillar of the vehicle.

[0015] It is to be understood that the pillar portion 22 can be removedfrom the roof portion 12, approximately along a line extended from thewindshield opening 18, providing a roof portion 12 that does not includea pillar portion 22.

[0016] The roof portion 12 is bounded on its outer peripheral sides byan attachment flange 24 that circumferentially surrounds the entire roofpanel 10, except for region adjacent to the windshield opening 18. Theattachment flange 24 is provided to allow an area to attach the roofpanel 10 to the underlying roof structure as well as to provide alocation for other body panels to intersect with the roof panel 10.

[0017] The roof rack portion 14 includes a raised or embossed portion 26defining the periphery of the roof rack portion 14. In the illustratedembodiment, the raised portion 26 has a front section 28 and two spacedapart, generally parallel and opposing side sections 30, 32 defining theroof rack portion 14. It is to be understood that a fourth rear section,can be utilized should the roof rack portion 14 not be located at therear most end of the roof panel 10. The fourth rear section, ifincluded, would complete the boundary of the roof rack portion 14.Alternatively, the roof rack portion 14 could include only the two sidesections 30, 32.

[0018] Each raised side portion 30, 32 projects upwardly from the planarsurface 16 of the roof portion 12 and extending longitudinally betweenopposite first and second ends 34, 36. Each raised side portion 30, 32further includes an outside surface 38 and an inside surface 40. Theoutside surface 38 has an appropriate radius of curvature to provide anaerodynamic transition to the roof portion 12 and the attachment flange24. An appropriate radius is based on the aesthetics of the roof rackdesign as well as other considerations, such as, the necessary height ofthe raised portion 26, and the appropriate wind resistance qualities ofthe raised portion 26.

[0019] The inside surface 40 provides a transition to the roof rackportion 14. The interior surface 40 of the two side portions 30, 32 haveintegrally formed pockets 42, 44 created or recessed therein forreceiving and securing a side rail 46 to each of the side portions 30,32. The pockets 42, 44 define an elongated channel having a generallyU-shaped cross-section and extending between the first and second ends34, 36 of the side portions 30, 32.

[0020] Referring to FIGS. 1 and 2, the side rail 46 is preferably formedof metal to withstand the wear and forces placed upon it during use.Each side rail 46 extends longitudinally between opposing first andsecond ends 48, 50 and has a generally C-shaped cross section with achannel 52 formed therein for receiving a connector 54. The side rails46 further include a plurality of spaced apart notches, or slots, 56formed in either the top or bottom edge of the channel 52 defining anadjustment boundary 58 therebetween to positively locate and secureconnector 54 to the side rail 46. The side rails 46 can be molded intothe pockets 42, 44 during the molding operations or the side rails 46may be attached or bonded inside the pockets 42, 44 after the roof panel10 has been formed.

[0021] A connector 54 is designed to slidably engage each of therespective side rails 46 via the channel 52 to allow for slidablemovement of the connector 54 between the first and second ends 48, 50 ofthe side rails 46. The connector 54 includes a rail engagement portion58 having a generally T-shaped cross section for corresponding matingengagement within the C-shaped channel 52 to facilitate the slidingengagement of the connector 54 with the side rail 46. Further, the railengagement portion 58 includes a spring bias locking tab 60 for engagingone of the notches 56 in the side rail 46, to positively lock theconnector 54 in place along the longitudinal length of the side rail 46.

[0022] The connector 54 further includes an arcuate shaped extensionneck portion 62 extending outwardly from the rail engagement portion 58and terminating at a distal cross bar engagement portion 64. Theengagement portion 64 is generally rectangular in cross section andstepped down from the neck portion 62 forming a male end fitting. Theneck portion 62 and the engagement portion 64 are designed to allowattachment of an elongated cross bar 66 that transversely extends acrossthe roof rack portion 14 and between the side rails 46 in the opposingside sections 30, 32. The cross bar 66 extends between opposite distalends and includes a generally hollow rectangular or oval cross sectionalshape. The engagement portion 64 is received in ends of the cross bar 66in a telescoping male/female type arrangement. The cross bar 66 may befixedly attached to the connectors 54 by any type of fastener 68, suchas a screw, as depicted in the drawing, or may be attached using otherconventional means, including rivets, lock pins, or the like.

[0023] The cross bar 66 is preferably made of metal and has a slot 70formed in the center of the top surface thereof extending the length ofthe cross bar 66. The slot 70 allows for the attachment of accessoriesto the roof rack, such as a bicycle rack, ski rack or other similardevices. The roof panel 10, and specifically, the roof rack portion 14may include one or more cross bars 66 slidably coupled between the sidesections 30, 32 via the connectors 54 in a parallel arrangement.

[0024] The roof rack portion 14 further includes a generally planarcentral portion 72 that is within the interior periphery defined by theraised portion 26. The central portion 72 has a plurality of spacedapart and generally parallel raised skid channels 74 formed therein toprovide a skid plate or raised area such that items placed in the roofrack portion 14 will not rub on the central portion 72. The raised skidchannels 74 also serve to strengthen the roof rack portion 14 andprovide heightened rigidity to support the forces exerted upon it whencarrying an item.

[0025] The roof rack portion 14 also includes a brake light platform 76on which a central or third brake light (CHMSL) that is required on mostvehicles can be mounted. It is to be understood that the roof rackportion 14 can be formed without the brake light platform 76.

[0026] In use, the cross bars 66 are slidably adjustable along the siderails 46 by depressing or releasing the locking tabs 60 and moving theopposing connectors 54 to desired corresponding locations on theopposing side rails 46 defined by the notches 56. The locking tabs 60are then released to engage with a corresponding notch 56 to lock theconnectors 54 in place along the side rails 46. In this manner, thespacing of the cross bars 66 can be customized to accommodate amultitude of orientations for various uses.

[0027] While the invention has been illustrated in detail in thedrawings and in the foregoing description, the same is to be consideredas illustrative and not restrictive in nature. It is understood thatonly the preferred embodiments have been shown and described fully andthat all changes and modifications that come within the spirit of theinvention are desired to be protected.

[0028] Thus, it is to be appreciated from the preceding disclosures thatthere has been described a roof panel having an integrally formed roofrack portion.

What is claimed is:
 1. A vehicle roof panel assembly comprising: a onepiece panel having a generally planar surface and an embossed portiondefined by longitudinally extending and generally parallel, spacedapart, side portions; at least one connector coupled to each of saidside portions; and at least one cross member extending transverselybetween said side portions and coupled to said connectors, wherein saidside portions and said connectors space said cross member from saidplanar surface.
 2. A vehicle roof panel assembly as set forth in claim 1wherein said connectors are slidably coupled to said respective sideportion for providing selective sliding adjustment of said cross memberalong the longitudinal length of said side portions.
 3. A vehicle roofpanel assembly as set forth in claim 2 further including an elongatedside rail fixedly attached to each of said side portions for slidablyconnecting said cross member and said connectors to said side portions.4. A vehicle roof panel assembly as set forth in claim 3 wherein each ofsaid side portions includes an elongated pocket forming a recessedchannel therein for receiving and supporting said side rail.
 5. Avehicle roof panel assembly as set forth in claim 4 wherein said siderail includes a generally C-shaped cross-section defining an elongatedchannel and said connector includes a rail engagement portion having agenerally T-shaped cross-section for sliding and interlocking engagementin said channel of said side rail.
 6. A vehicle roof panel assembly asset forth in claim 5 wherein said side rail includes a plurality ofspaced apart notches therein for cooperative engagement with a lockingtab coupled to said connector for releasably locking said connectoralong said side rail.
 7. A vehicle roof panel assembly as set forth inclaim 6 wherein each of said connectors includes an extension neckportion extending from said rail engagement portion from said channelfor supporting said cross member above said planar surface of said roofpanel.
 8. A vehicle roof panel assembly as set forth in claim 7 whereinsaid roof panel assembly includes a roof portion and a roof rack portiondefined by said embossed side portions.
 9. A vehicle roof panel assemblyas set forth in claim 8 wherein said roof panel assembly includes aplurality of spaced apart and generally parallel raised skid channelsprotruding from said planar surface.
 10. A vehicle roof panel assemblyas set forth in claim 9 wherein said roof panel is formed of a solidlong-fiber reinforced thermoplastic.
 11. A vehicle roof panel assemblyas set forth in claim 9 wherein said roof panel is formed of a stampedsheet metal.